Wire arc accuracy adjustment system

Abstract

Provided are a systems and methods for continuously providing a metal wire to a welding torch in the correct orientation with respect to the heat source of the welding torch for manufacturing objects by solid freeform fabrication to provide continuous deposition of metal to the freeform object, especially objects made with titanium or titanium alloy, or nickel or nickel alloy, wire.

Description

[0001]This application is a continuation application of prior U.S. patent application Ser. No. 15 / 206,171, filed Jul. 8, 2016, the entire contents of which are incorporated herein by reference.FIELD OF THE INVENTION[0002]The present application relates to a system and method of maintaining the accurate placement of a distal end or tip of a metal wire into the arc of a welding torch for manufacturing objects by solid freeform fabrication, especially objects made from titanium and titanium alloy, or nickel or nickel alloy, wire.BACKGROUND OF THE INVENTION[0003]Structured metal parts made of titanium or titanium alloys are conventionally made by casting, forging or machining from a billet. These techniques have a disadvantage of high material use of the expensive titanium metal and large lead times in the fabrication.[0004]Fully dense physical objects may be made by a manufacturing technology known as rapid prototyping, rapid manufacturing, layered manufacturing, solid freeform fabrica...

AI Technical Summary

Benefits of technology

This patent is about a system and method for rapid and accurate layered manufacturing of objects using metal wire and welding torches. The system keeps the metal wire in the correct position relative to the heat source emitted by the welding torch, ensuring a constant supply of melted metal to the molten pool on the surface of the work piece. It also addresses the needs for an improved, economical method of performing direct metal deposition by utilizing systems and methods for delivery of metal wire to the welding torch. The invention can increase throughput and yield of distortion-free direct metal deposition formed parts with smooth, well-defined boundaries. The adjustment during the manufacturing process can maintain the distal end of the metal wire in the desired location relative to the arc of the welding torch, providing a continuous supply of metal wire to the torch. The system also includes a master feed device and a fixed main support frame or an adjustable guide support frame with cut-outs, perforations, or holes to maximize heat dissipation while minimizing any detrimental effect on mechanical strength of the frame.

Problems solved by technology

These techniques have a disadvantage of high material use of the expensive titanium metal and large lead times in the fabrication.

The accuracy of the welding technique is usually too coarse to allow directly forming the object with acceptable dimensions.

If the metal wire is not maintained within the arc, it will not melt properly or be deposited in the correct position.

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